Orthotic footplate

ABSTRACT

An orthotic footplate including at least two superimposed, discrete structural layers having different lengths that extend along at least a segment of a length of the footplate. The footplate defines regions with different thicknesses and stiffness.

This application claims the benefit of U.S. Provisional Application Nos.60/500,227 filed Sep. 5, 2003, 60/512,203 filed Oct. 20, 2003, and60/576,294 filed Jun. 3, 2004.

BACKGROUND

Foot orthotics are often used to compensate for impaired foot functionby controlling abnormal motion across the joints of the foot. Specificimpairments that a foot orthotic may assist include mild “foot drop” dueto neurological conditions, orthopedic gait abnormality, clubfoot,mid-tarsal fracture, partial foot amputation, arthritis, hallux valgus,hallux rigidus, turf toe, and plantar fasciitis. Foot orthotics may alsobe prescribed to reduce pain, to provide support, to prevent footdeformity or prevent the worsening thereof, to relieve pressure on acertain area of the foot, and to improve the overall biomechanicalfunction of the foot and lower extremity limbs.

In their basic form, functional foot orthotics or orthotic footplateswork like shock absorbers, removing pressure and stress from painfulareas of the foot and ankle while controlling abnormal position andmovement of the foot. Moreover, they promote the proper alignment of thefeet and can restore balance. Orthotic footplates operate to hold theheel and middle portion of a foot in a more stable position when aperson is walking or standing, and thus allow the foot to function moreefficiently during weight-bearing and propulsion.

Known orthotic footplates tend to have an equal stiffness along theirlength. It has been found, however, that a footplate having equalstiffness may further contribute to an abnormal gait by overcompensatinga foot at a toe portion. More specifically, during toe-off of a gaitcycle, the toe portion has a tendency to bend around the largest momentof the footplate. This, in turn, results in a considerable amount ofpressure being placed on the plantar surface of the foot. Hence, theseorthotic footplates may actually worsens a condition and createorthopedic problems elsewhere in the body.

Accordingly, it is desirable to provide an orthotic footplate that has astiffness gradient that corresponds to ground reaction forces as theyare applied to a foot and released by a foot during a swing phase of agait cycle, while providing the necessary support and shock absorptionto a foot during a stance phase of a gait cycle.

In addition to foot impairment, an ankle-foot orthosis is oftenprescribed for users having gait deviations that relate to muscleweakness. An ankle-foot orthosis substitutes or compensates for weakdorsiflexors during the swing phase and for weak plantarflexors duringthe stance phase of a user's gait. In effect, an ankle-foot orthosis canbe used to support and align the ankle and the foot, suppress spasticand overpowering ankle and foot muscles, to assist weak and paralyzedmuscles of the ankle and foot, to prevent and correct ankle and footdeformities, and to improve the functions of the foot.

Many known ankle-foot orthoses are configured to concentrate on theankle and knee biomechanics while only providing minimal support to thefoot. It has been found, however, that users of ankle-foot orthosesrequire at least some foot support of the type offered by theaforementioned orthotic footplates.

Accordingly, it is desirable to provide an ankle-foot orthosis having anorthotic footplate that improves biomechanical function of the foot,ankle and knee. Furthermore, it is desirable to provide an ankle-footorthosis imparting improved stability of a foot and leg overconventional ankle-foot orthoses while maintaining a lightweightstructure that comfortably secures to a user's foot while providingsuitable support.

SUMMARY

According to an embodiment of the present invention, an orthoticfootplate is provided having variable elasticity and adapted to providea support for a user foot. The footplate generally defines a line ofprogression that extends from a heel portion to a middle portion to atoe portion. The footplate comprises a layered structure of two or morediscrete structural layers. Each layer extends along at least a segmentof a length of the footplate wherein different regions are definedhaving different thicknesses and stiffness. In this embodiment, thedifference in thickness of the footplate is defined as beingsubstantially perpendicular to a line of progression extending from aheel portion to a middle portion to a toe portion of the footplate.

Corresponding to a feature of an embodiment of the footplate, the firststructural layer is coextensive with the length of the footplate,whereby the first layer generally defines the periphery of thefootplate. Additional structural layers are superimposed on a surface ofthe first structural layer of the footplate wherein ascending structurallayers generally decrease in length relative to the first layer.

The additional structural layers each have an edge thickness thatextends substantially perpendicular from an adjacent lower structurallayer. In variations of this embodiment, edge thickness differences mayalso have a convex or a concave shape. By arranging an edge thicknessthat is substantially perpendicular to the line of progression enableeasier control of the flexibility of the footplate as opposed to whenthe edge thickness is concave or convex. The distance between borderswhere the thickness between two or more layers is different determinesat least partly the flexibility of the footplate in a way that theflexibility is more continuous when the distance is short ordiscontinues when the distance is increased.

According to a variation of the embodiment, the first structural layeror the additional structural layers are woven with fibers runningsubstantially 45° and −45° to the line of progression. The layer orlayers may be arranged unidirectionally with fibers runningsubstantially parallel to the line of progression.

The stiffness and elasticity of the footplate may be tuned by varyingthe number of the layers, by varying the thickness of the layers,varying the material of the layers, or a combination thereof.

The distance between the borders where the thickness between two or morelayers is different determines at least partly the flexibility of thefootplate in a way that the flexibility becomes more continuous when thedistance is short or discontinues when the distance is increased.

According to a variation of the footplate, the footplate may compriseadditional areas of different thicknesses and thereby elasticity adaptedto guide the gait pattern of an impaired foot to a normal gait pattern.

In another variation of the footplate, the footplate comprises a legsupport fastened to the footplate, wherein the size and shape of the legsupport may be varied depending on the application and the gaitpathology of a user.

The embodiments of the orthotic footplate provide enhanced gaitefficiency and comfort for those with partial foot amputation or otherinjuries requiring immobilization. Furthermore, the embodiments of theorthotic footplate offer a durable and dynamic footplate that impartsgood support. When selected for the correct weight and activitycategory, the footplate redistributes effectively the forces directedonto the foot, allowing the most natural gait possible. As a result ofits configuration, the orthotic footplate may be either customized orprefabricated to satisfy a variety of criteria and foot sizes.

According to another embodiment of present invention, an ankle-footorthosis device having a footplate with variable elasticity is provided.The ankle-foot orthosis includes an embodiment of the footplate that hasa line of progression extending from a heel portion to a middle portionto a toe portion. The footplate includes at least two superimposed,discrete structural layers each having different lengths and extendingalong at least a segment of a length of the footplate such that thefootplate defines regions with different thicknesses and stiffness. Theankle-foot orthosis also includes a leg support that is connected to theheel portion of the footplate.

Corresponding to this embodiment of the ankle-foot orthosis, theankle-foot orthosis includes a securing device that is arranged tosecure the leg support to a user's leg. The securing device includes aslot that is configured to accommodate an end portion of the legsupport, and a fastening device that has elastic properties and connectsto the leg support to permit the securing device to move relative to theleg support.

In another variation of the ankle-foot orthosis, the leg supportincludes a spring member that connects to the heel portion of thefootplate, and a leg shell having outwardly extending side portionsadapted for supporting a user's leg. The footplate also includesoutwardly extending side portions extending from the middle portion andaround the heel portion of the footplate.

According to yet another embodiment of the ankle-foot orthosis, the legsupport comprises first and second spring members that are eachconnected at one end to a heel portion of a foot support. A connectingelement is provided which secures the first and second spring memberstogether. The first spring member is connected at another end to a calfsupport member having two outwardly extending side portions adapted forsecuring to a user's leg.

The embodiments of the ankle-foot orthosis impart the benefits of theembodiments of the orthotic footplate described herein while resolvingvarious problems related to biomechanics. The ankle-foot orthosesdescribed herein can provide support, protection or replacement of lostfunction to users having foot, ankle and leg impairment.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and accompanying drawings where:

FIG. 1 shows a top plan view of an embodiment of an orthotic footplate;

FIG. 2 shows an elevational view of the orthotic footplate of FIG. 1;

FIG. 3 shows a schematic view of several layers of the orthoticfootplate of FIG. 1;

FIG. 4 is a perspective view of the orthotic footplate of FIG. 1;

FIG. 5 is a perspective view of a variation of the orthotic footplate ofFIG. 1;

FIGS. 6-11 are schematic views showing dynamic energy storage and energyreturn of the orthotic footplate of FIG. 1;

FIGS. 12 and 13 are schematic elevational views showing flexure of aheel portion of embodiments of an orthotic footplate;

FIG. 14 is a schematic top plan view of another embodiment of anorthotic footplate;

FIG. 15 is a schematic top plan view of another embodiment of anorthotic footplate;

FIG. 16 is a schematic top plan view of another embodiment of anorthotic footplate.

FIG. 17 is a selection chart used in the selection of orthoticfootplates;

FIGS. 18 and 19 are graphical representations showing a plot having aprogression of center of pressure as a function of time;

FIG. 20 is perspective view of an embodiment of an ankle-foot orthosisaccording to the invention;

FIG. 21 is an elevational view of the ankle-foot orthosis of FIG. 20;

FIG. 22 is an elevational view showing the footplate of FIG. 20;

FIG. 23 is a perspective view showing a variation of the ankle-footorthosis of FIG. 20;

FIG. 24 is a perspective view showing a variation of a footplate of theankle-foot orthosis of FIG. 20;

FIG. 25 is a perspective view of an embodiment of an ankle-footorthosis;

FIGS. 26 and 27 are elevational views showing an embodiment of anankle-foot orthosis;

FIGS. 28-30 are schematic views showing dynamic energy storage andenergy return of the ankle-foot orthosis of FIG. 20;

FIG. 31 is a selection chart used in the selection of ankle-footorthoses; and

FIG. 32 is a graphical representation showing momentum of plantarflexorsand dorsiflexors during a stance phase and swing phase in one leg.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

A. Overview

A better understanding of different embodiments of the invention may behad from the following description read in conjunction with theaccompanying drawings in which like reference characters refer to likeelements.

While the disclosure is susceptible to various modifications andalternative constructions, certain illustrative embodiments thereof areshown in the drawings and will be described below in detail. It shouldbe understood, however, that there is no intention to limit thedisclosure to the specific embodiments disclosed, but on the contrary,the intention is to cover all modifications, alternative constructions,combinations, and equivalents falling within the spirit and scope of thedisclosure and defined by the appended claims.

It will be understood that, unless a term is expressly defined in thispatent to possess a described meaning, there is no intent to limit themeaning of such term, either expressly or indirectly, beyond its plainor ordinary meaning.

Any element in a claim that does not explicitly state “means for”performing a specified function, or “step for” performing a specificfunction, is not to be interpreted as a “means” or “step” clause asspecified in 35 U.S.C. § 112, paragraph 6.

B. Environment and Orientation of Footplate

In each of the embodiments described herein, the orthotic footplatedefines a line of progression extending from a heel portion to a middleportion to a toe portion of the footplate. The line of progressionbasically defines a position curve of center of mass along the footduring a stance phase. While various embodiments described herein havedifferent properties and structural configurations, each footplategenerally posseses the abovementioned portions. Moreover, the footplatemay be divided into more portions, however, for simplicity and the sakeof explanation, the following disclosure will remain limited to theabovementioned portions.

In accordance with the orthotic footplate, it will be understood thatgreater stiffness of the footplate is achieved at least by increasingthe amount of layers or the thickness thereof at certain portions of thefootplate. Conversely, greater elasticity is obtained at least in partin portions of the footplate having fewer or thinner layers.

The orthotic footplate may be modified to include a variety of differentlayers and define different thicknesses, lengths and shapes. It is to beunderstood that it is envisioned that as with users having differentfoot sizes and shapes, the orthotic footplate may likewise be modifiedto define such corresponding sizes and shapes.

Reference will be made herein to the gait cycle of a human being. Thegait cycle is broken down into two components: the swing phase and thestance phase.

The swing phase last from the point when the toe leaves the ground untilthe moment when the heel comes into contact with the ground. At toe-offthe foot is in a supinated position, and to assist in clearing the toefrom the ground, it originally pronates. The remainder of the swingphase, the foot supinates prior to bringing the heel to the ground forthe stance phase of the gait cycle.

The stance phase may be broken down into three portions: contact,midstance and propulsion. During the contact portion, the foot acts toabsorb the shock of each step. The foot pronates to become more flexiblein order to prevent transmission of the full force of each step to moreproximal structures. During the midstance portion, the foot begins tosupinate, transforming from a flexible shock absorber to a rigid levelfor propulsion. This period ends when the heel lifts off the ground, andthe propulsive period begins. In the propulsion phase, the footcontinues to supinate, propelling the body forward and ends withtoe-off.

C. Description

FIGS. 1-3 show an embodiment of an orthotic footplate 38 that is adaptedto respond to ground reaction forces applied during various activities,such as compensation for loss of biomechanic foot-function. Thefootplate 38 defines line of progression 40, toe portion 42, middleportion 44, and heel portion 46. In this embodiment, the footplate 38has a constant elasticity in the middle portion 44, but varies stiffnessat the toe and heel portions 42, 46.

In this embodiment, the peripheral shape of the footplate 38 is definedby a first discrete structural layer 48 that essentially defines adistal or bottom portion of the footplate 38, and is generally arrangedfor facing towards a walking surface. The first layer 48 generallycorresponds to the shape of a user's foot (not shown). Additionaldiscrete structural layers 50, 52, 54, 56, 58, 60 are generallysuperimposed on the first layer 48 and extend proximally therefrom. Eachlayer rising from the first layer 48 is generally shorter in length thanthe first layer 48, wherein the length of the additional layers arereduced in both the toe and heel portions 42, 46.

FIG. 4 schematically shows the difference in length of the additionallayers 50, 52 extending proximally from the first layer 48.

While the thickness of each of the layers 48, 50, 52 is generally shownas the same, the thicknesses of each of the layers may be individuallyincreased or descreased in order to obtain desirable properties such asstiffness.

Since the thickness difference of the layers is used to change theelasticity of the footplate, and thereby the stiffness, the edges ofeach of the additional layers at the toe and heel portions 42, 46 aregenerally linear and perpendicular to the line of progression 40. It hasbeen found that when the edges are not perpendicular to the line ofprogression, it is difficult to control the elasticity of the footplatesince non-uniform edges, such as those that are concave or convexshaped, have a tendency to generate a stiffness gradient across thelength thereof It will be understood, however, that the embodimentsdescribed herein may have layers with edges oriented relative to theline of progression that are concave, convex, stepwise, linear,serrated, and combinations thereof if a stiffness gradient across thewidth of the footplate is desired. It will be noted, however, thatattention must be made to ensure that the stiffness gradient does notadversely affect the function of the footplate.

The structural material of the layers preferably comprises carbon fibersimpregnated with a thermoplastic material, such as polypropylene ornylon, or a resin. Alternatively, other structural materials may be usedalone or in combination with carbon fibers. Such other structuralmaterials include Kevlar aramid fibers, glass fibers or combinationsthereof. The fibers are preferably impregnated with an epoxy resin orother suitable resin system. Alternatively, the footplate may be moldedor comprise a plurality of polymeric layers, such as polypropylene,polyurethane or polyethylene. In each of the embodiments, the layers arebonded by using methods known to those skilled in the art.

According to one embodiment, the carbon fibers of the first layer arewoven in an orientation substantially 45° and −45° to the line ofprogression. An advantage of having the fibers running substantially 45°and −45° to the line of progression is to prevent subsequent layers fromuntwisting. Alternatively, the fibers may be arranged in differentorientations relative to the line of progression. The additional layersmay be arranged similarly as the fibers in the first layer or in otherorientations.

At least some of the additional layers may be unidirectional fibers thatare oriented in generally single direction running substantiallyparallel to the line of progression. The orientation of these fibers isprovided to maintain a large stiffness in a walking direction and tothereby minimize the thickness of the layer.

The footplate may be canted along different portions along the line ofprogression. As exemplified in FIG. 2, angle A is defined between themiddle portion 44 and heel portion 46, wherein the transition of angle Aoccurs generally within the middle portion 44. Also, angle B existsbetween the toe portion 42 and the middle portion 44. By varying theheight of the heel portion 46 and the height of the toe portion 42, onemay facilitate roll over of a foot. A variety of angles for angles A, Bare envisioned, with preferred angles ranging between 0-30°. Of course,other angles are possible and may be selected to accommodate a shoe typeand a user's needs. Moreover, each of the portions of the footplate maycomprise additional areas that are canted or have extended or shortenedareas of transition.

With the exemplary footplate 38 shown in FIGS. 1-3, a footplate isprovided having different areas of stiffness and flexibility so as toredistribute forces applied to the foot. The footplate increases thestability of the foot, releases energy and propels a user's foot and legat toe-off. Moreover, the footplate raises a user's toes for clearanceduring the swing phase. The configuration of the footplate results inenergy storage and energy release as it undergoes flexion and deflexionduring a user's gait.

According to different embodiments of the footplate, the length of theadditional layers may be varied according to a desired stiffness indesignated areas. The footplate 62 in FIG. 5 is exemplary inillustrating a first layer 64 and additional layers 66, 68, 70, 72having different lengths across the toe, middle and heel portions 42,44, 46. The second layer 66 generally extends into both the toe and heelportions 42, 46 of the footplate 62 in different proportions. In thisembodiment, the second layer 66 extends into the heel portion 46coextensively with the first layer 64, yet extends into the toe portion42 less than the first layer 64. The configuration of the second layer66 in this embodiment results in a stiffer heel portion 46 compared tothe toe portion 42. The third layer 68 extends more into the heelportion 46 than in the toe portion 42 of the footplate 62, once againcontributing to a stiffer heel portion 46. The fourth layer 70 extendsmore into the toe portion 42 than in heel portion 46 thus providinggreater stiffness at the toe portion 42. Lastly, the fifth layer 72defines a more elongate middle portion 44 of the footplate 62.

FIGS. 6-11 exemplify the energy storage and return of the footplate 38in the embodiment of FIG. 1. FIG. 6 shows an impaired foot 74 of a useron the footplate 38 in a neutral position. In FIG. 7, the weight W ofthe user is exerted onto the toe portion 42 of the footplate which urgesthe footplate 38 to bend at the toe portion 42 and stores energy in thefootplate 38. FIG. 8 shows the release of the weight W whereby energy Sis released and propels the foot 74 at toe-off. In FIG. 9 the weight Wof the user is used to bend the footplate 38 at the heel portion 46 andcauses energy to be stored in the footplate 38. FIG. 10 shows therelease of the weight W and the spring of the energy S to release. FIG.11 shows the foot 74 pressing onto the footplate 38 in a neutralposition similar to FIG. 6.

FIGS. 12 and 13 show heel portions of first and second differentfootplates 76, 84, and demonstrate how varying the amount of structurallayers affect the flexure of the footplate. For exemplary purposes, eachof the first and second footplates 76, 84 generally has the same overallthickness. The first footplate 76 includes three structural layers 78,80, 82 that define a total thickness that is generally the same as atotal thickness of six structural layers 86, 88, 90, 92, 94, 96 of thesecond footplate 84. The three structural layers 78, 80, 82 each have agreater thickness than each of the six structural layers 86, 88, 90, 92,94, 96.

As can be seen in the depiction in FIGS. 12 and 13 of the flexedfootplates 76, 84, the flexure of the first footplate 76 is lesscontinuous and smooth than the flexure of the second footplate 84. Thus,embodiments of the footplate may be varied according to a desiredsmoothness of flexure of the footplate. It will also be pointed out thatwhile the structural layers are shown as generally having the samethickness, the footplate is not limited to structural layers having auniform thickness and may be modified to include a variety of structurallayers having different thicknesses.

FIGS. 14 and 15 illustrate first and second embodiments of orthoticfootplates 98, 106 having structural layers of different shapes andsizes. As shown in FIG. 14, the first embodiment 98 includes threesuperimposed layers 100, 102, 104 that generally have the same but areof different proportions relative to one another. Alternatively, FIG. 15shows the second embodiment 106 including three superimposed layers 108,110, 112 wherein the first layer 108 generally defines the shape of afoot, and second and third layers 110, 112 generally follow thecontoured shape of the first layer 108 except at the ends of the toe andheel portions which are substantially defined as linear edges.

It will be pointed out that it is within the scope of this invention toprovide a variety of different superimposed structural layers havingdifferent shapes, areas, lengths, thicknesses, and other propertiesaimed at providing tailoring of the orthotic footplate to address theneeds of a user.

FIG. 16 shows another embodiment of an orthotic footplate 114 similar tothe embodiment of FIG. 10 yet differing therefrom by including theadditional feature of having areas 116, 118, 120 of different thickness.The footplate 114 defines two lines of progression 122, 124 wherein thefirst line 122 defines a normal line of progression for a healthy footand the second line 124 defines the line of progression for a particularimpaired foot. The areas of differing thickness 116, 118, 120 areprovided to accommodate a particular impaired foot by guiding the gaitpattern to follow the normal line of progression 122.

The areas defining different thicknesses may be formed by additionalsegments of structural material or layers, and the structural layersthemselves may have a non-uniform thickness which when superimposed withone another yields such areas of differing thickness.

FIG. 17 represents a selection chart of different footplates, which aredivided into four weight categories and three rigidity categoriesincluding minimum, medium and maximum rigidity.

A footplate having maximum rigidity may be prescribed for users thathave at least some of the following characteristics:

lack of a full-length toe-lever due to amputation of (parts of) thefoot;

lack of a full-length toe-lever due to congenital deformities of thefoot (for example, clubfoot);

severe and painful limitations of the distal joints of the foot that donot tolerate a normal amount of dorsiflexion at the metatarsal break;

severe cases of Hallux Valgus where no dorsiflexion tolerated.

A footplate having medium rigidity is recommended for users that have atleast some of the following characteristics:

lack of part of the full-length toe-lever due to amputation of one ormore of the toes;

considerable limitations of the meta-tarsophalangeal and interphalangealjoints of the toes due to any form of degenerative diseases that do nottolerate a normal amount of dorsiflexion of the metatarsal break;

severe hallux limitus to halux rigidus;

considerable Hallux Valgus.

A footplate having minimum rigidity may be prescribed for users thathave at least some of the following characteristics:

light-weight users that lack part of the full-length toe-lever due toamputation of one or more of the toes;

mild limitation of the meta-tarsophalangeal and interphalangeal jointsof the toes due to any form of degenerative diseases, that do nottolerate a normal amount of dorsiflexion at the metatarsal break;

mild hallux limitus to halux rigidus;

early stage hallux valgus.

FIGS. 18 and 19 graphically illustrate the progression of center ofpressure “COP” (mm) as a function of time for a stance phase of a user'sgait. At the beginning of the stance phase, the COP lies on themedial-posterior heel. The COP then moves through the mid-foot regionand continues towards the forefoot, crossing the metatarsal heads toterminate in the region of the largest and the second toe. Significantdistorsions of this pattern can give evidence of abnormal loads on thefoot and of problems in the correct progression of a gait stride.

The graphical representation in FIG. 18 is based on measurements of auser wearing a plastic ankle-foot orthosis. Curve 130 marked as “healthyside” is used as a reference curve and represents a healthy foot. Curve132 marked as “ankle-foot orthosis only” represents a user wearing onlyan ankle-foot orthosis without a footplate according to this disclosure.Curves 134 and 136, marked as “Gradient, cat. 2” and Gradient, cat. 3,”respectively, define conditions of a user is wearing one of twodifferent categories of orthotic footplates according to this disclosurethat have different elasticity in combination with a plastic ankle-footorthosis.

FIG. 19 is an exploded view of a portion of the plot shown in FIG. 18.The plateau 138 for curve 132 representing the ankle-foot orthosisindicates a poor gait pattern, whereas curves 134, 136 have a pathsubstantially similar to the curve 130 of a healthy foot which isaligned in a proper orientation due to the footplate.

Evaluation of the graph shows the following results: at initial contact,the user shows an irregular progression of the center of pressure whenonly wearing the ankle-foot orthosis. The progression is shown as beingslow and not smooth which is represented by peak 140. For both of thefootplates used, at initial contact the progression is shown as beingsmoother and closely approximating the curve 130 of a healthy foot.

Looking at the midstance of curve 132, very little and slow progressionof the COP is shown. Combining the ankle-foot orthosis with a footplateof category 2, the progression is smoother and faster. By the sametoken, when combining the ankle-foot orthosis with a footplate ofcategory 3 a fluent progression of the center of pressure is measured.

Turning to ankle-foot orthosis embodiments of the invention employingembodiments of the above-mentioned orthotic footplate, FIGS. 21 and 22illustrate an embodiment of an ankle-foot orthosis adapted to assist thebiomechanics of the foot, ankle and lower leg. In this embodiment, theankle-foot orthosis 200 comprises a footplate 202 and a leg support 204substantially formed as a single unit. The shape of the leg support 204is generally defined as having a custom shape of a calf of a user, ormay be based on a common calf shape. The length of the leg support 204may easily be varied depending on the application and the user.

In the ankle-foot orthosis 200, thickness differences between adjacentlayers are only shown in the footplate 202, which was generallydiscussed above in reference to the embodiment shown in FIG. 1

The ankle-foot orthosis 200 further includes a securing device 206 forextending circumferentially around a user's leg (not shown). Thesecuring device 206 includes two end portions 216, 218 having agenerally curvilinear profile, and a connecting element 214 connectingthe end portions 216, 218. The securing device 206 is arranged to slideon the leg support 204 through a slot 208 which acts as a sliding meansfor the leg support 204. According to this embodiment, the slot 208 ofthe securing device 206 is closed at one end to prevent the leg support204 from sliding therethrough.

The ankle-foot orthosis 200 includes a fastening device 210 that haselastic properties and extends from the securing device 206 to connectto the leg support 204. The securing device 206 is movable relative tothe leg support 204 via the fastening device 210. According to thisembodiment, the fastening device 210 is detachably secured to the legsupport 204 by a conventional hook and loop fastener system 212. Ofcourse, it will be understood that other fastener systems may be usedsuch as bolts, screws, pins, and snaps. The fastening device 210 enablesmobility of the leg support 204 relative to the securing device 206 inthe direction D. This feature of the ankle-foot orthosis 200 preventsrubbing between the securing device 206 and a user's body.

The number of layers in the footplate 202 of the ankle-foot orthosis 200in FIGS. 20 and 21 may be varied, depending on the application and thegait pathology of a user. More specifically, FIGS. 20 and 22 showboundaries between five different layers 220, 222, 224, 226, 228 of thefootplate. In this embodiment, a first layer 220 adjacent to the groundsurface defines the shape of the footplate, and the subsequent layers222, 224, 226, 228 superimposed on the first layer 220 havesubstantially the same shape as the first layer 220 except at a toeportion 229, where they are shortened with each subsequent superimposedlayer. The border between each of the superimposed layers 222, 224, 226,228 is defined as an edge thicknesses generally extendingperpendicularly from the adjacent layer.

These thickness differences between adjacent layers create differencesin elasticity across the footplate. The result of such layered structureis an ankle-foot orthosis comprising a footplate of differentflexibility where certain regions have different stiffness. The layeringof the footplate creates different stiffness and flexibility of thefootplate, and redistributes forces applied to the foot and where thestiffness gradient of the front part of the footplate corresponds to theground reaction forces as they are applied by the foot.

FIG. 22 shows different toe and heel heights 232, 234, respectively, ofthe footplate. By varying the toe height 232 and the heel height 234,one may facilitate roll over of the footplate 202 of the ankle-footorthosis 200. Since momentum is largest at the heel portion 230 of thefootplate 202, it is preferred that the heel portion 230 is the thickestpart of the footplate 202. The shape of the heel portion 230 may bedetermined by the shape of a shoe such that it will fit snugly insidethe shoe and but will not excessively rub against the shoe or a user'sheel.

The ankle-foot orthosis may be constructed from a variety of materials.According to one embodiment, the ankle-foot orthosis comprises at leasttwo structural layers including a plurality of fibers impregnated with apolymeric material. In this embodiment, the fibers of a first layeradjacent to a ground surface are generally oriented at an oblique anglerelative to a line of progression of the footplate extending from a heelportion to a middle portion to a toe portion of the footplate.Preferably, but not limited, the fibers of the first layer extendrelative to the line of progression in a range of 15-75°. The polymericmaterial may be selected from the group consisting of polypropylene,nylon and epoxy resin. The plurality of fibers may be selected from thegroup consisting of carbon fibers, glass fibers, Kevlar aramid fibers,or other suitable structural fibers.

In embodiments of the ankle-foot orthosis, layers that are superimposedon the first layer may include fibers that are unidirectionally orientedgenerally parallel to the line of progression of the footplate.Alternatively, the fibers of each structural layer of the footplate maybe woven unidirectionally with fibers running substantially parallel toa line of progression of the footplate extending from a heel portion toa middle portion to a toe portion of the footplate.

According to methods for making the leg support of the ankle-footorthosis and integrating the same with the footplate, such methods aredefined in U.S. Pat. application Ser. No. 10/702,447 (U.S. PublishedApplication 2004/0134500) assigned to the assignee of the presentdisclosure and incorporated herein by reference.

The embodiments of the ankle-foot orthosis described herein may beprovided with silicone padding and a thermo-formable tube covering theheel portion of the leg support. This combination results in easierdonning of the ankle-foot orthoses and prevents damage of the padding ina vulnerable area. For example, flexible foam padding made fromcross-linked, closed cell polyethylene foam may be provided on variousparts of the orthosis to add comfort and enhance fit. In thealternative, silicone padding may be used from incompressible siliconethat optimizes pressure redistribution. The silicone padding is made ofsilicone and features a black textile cover. Commercial products include“Ossur AFO Dynamic Foam” and “Ossur Silicone Padding” sold by Ossur hf,of Reykavik, Iceland.

While this embodiment generally shows the leg support as correspondingto a posterior portion of a human leg, the leg support may be modifiedto extend along at least either the medial or lateral sides of a humanleg.

FIG. 23 shows a variation 236 of the embodiment of an ankle-footorthosis of FIGS. 20-22. According to this embodiment, the ankle-footorthosis 236 includes at least one calf shell 238 connected to the legsupport 204. The calf shell 238 includes at least two curvilinear sideportions 240, 242 extending from opposed sides of the leg support 204and generally extending along a length of a middle and end portions ofthe leg support 204. A foot shell 244 is connected to the footplate 202and has at least two curvilinear side portions 246, 248 extending fromopposed sides of the footplate 202. The foot shell 244 generally extendsalong a heel portion and at least a segment of a middle portion of thefootplate 202. A suitable connecting element 214 may be used to connectopposed sides of the calf shell 238. This embodiment may be varied toinclude only the calf shell 238 or the foot shell 240. A user canbenefit from the dorsal and plantarflexor assistance that the ankle-footorthosis provides and further obtain high medial-lateral stability fromthe calf and foot shells 238, 240. The calf and foot shells 238, 240 canbe made of a plastic material or a composite material system, andcustomized in size for the user.

While in the embodiment shown in FIG. 23 the calf shell 238 isintegrated with the leg support 204, the calf shell 238 may be securedto the leg support 204 by any known method that will securely fasten thecalf shell 238 to the leg support 204 to provide sufficient stability toa user. Likewise, the foot shell 240 may similarly be integrated withthe footplate 202 as shown in FIG. 23 or, in the alternative, the footshell may be secured to the footplate according to known methods.

FIG. 24 illustrates a variation of the footplate 202 of the ankle-footorthosis of FIG. 20. According to this variation, the footplate 202includes a damping device 250 positioned at the heel portion 230 of thefootplate 202. The damping device 250 generally extends at an inclinedangle relative to the distal surface of the footplate 202.

According to one embodiment, the damping device 250 is a heel wedge thatprovides smooth heel contact. According to another embodiment, polymersof different stiffness may be used to obtain different stiffness tomatch an activity level and body weight. In yet another embodiment, thedamping device may be separate from the ankle-foot orthosis, butarranged to accommodate the heel portion of the footplate. In thisembodiment, the damping device may be a wedge or spring is positionablewithin the shoe of a user. According to yet another embodiment, thedamping device may be a carbon fiber heel plate that extends from theheel portion of the footplate at an inclined angle to provide a springeffect during heel strike.

FIG. 25 shows another embodiment of an ankle-foot orthosis 250.According to this embodiment, a spring 252 is integrated with a calfshell 254 and a foot shell 256. The spring 252 and the foot shell 256are integrated with a footplate 258 of the type described in referenceto FIG. 1.

In the ankle-foot orthosis 250, the spring 252, and calf and foot shells254, 256 may be made from carbon, glass, or Kevlar aramid fibers incombination with an epoxy resin. In the alternative, the spring 252, andcalf and foot shells 254, 256 may be constructed from a polymericmaterial such as polypropylene or polyethylene, and may alternatively bereinforced with bars or other structural elements such as thoseconstructed from metal or composites.

Alternatively, the spring member 252 may be secured to the footplate 258and the calf and foot shells 254, 256 by known methods described hereinfor connecting orthotic components together.

FIGS. 26 and 27 show another embodiment of an ankle-foot orthosis 260having a first spring member 264 connected to a calf member 262 and afoot member 270. A second spring member 266 is connected with the footshell 270. The first and second spring members 264, 266 are connectedtogether with a connecting element 268. The connecting element 268 maybe a ring, clamp, hook-and-loop type fastener system, or any otherconnecting element suitable for connecting the first and second springmembers 264, 266.

As shown in both FIGS. 26 and 27, the connecting element 268 may bepositioned along the length of the first and second spring members 264,266 to provide for different flexibilities of the ankle-foot orthosis.For example, FIG. 26 shows the connecting element 268 positioned near aproximal portion of the first and second spring members 264, 266. Inthis configuration, plantarflexion and dorsiflexion of the ankle-footorthosis 260 are substantially the same. In the alternative, FIG. 27shows a configuration wherein the ankle-foot orthosis 260 providesgreater plantarflexion. Of course, it will be understood that theconnecting element 268 may be positioned anywhere between the calf andfoot shells 262, 270 along the first and second spring members 264, 266to obtain desired plantarflexion and dorsiflexion.

The first and second spring members 264, 266 may be integrated with thefoot member 270, or secured therewith by methods known to those skilledin the art including adhesives, pins, and a hook and loop fastenersystem. Moreover, the first spring member 264 may be secured to the calfmember 262 using similar methods used to secure to the foot member 270.According to this embodiment, the proximal end of the second springmember 266 is left unattached to the calf member 262 and is free toextend outwardly relative to the first spring member 264 depending onthe location of the connecting element 268.

The ankle-foot orthosis 260 includes a footplate 202 generally of thetype described above in relation to FIG. 20. The foot member 270 mayhave a portion the extends around the heel portion of the footplate 202to reinforce the heel of a user. Furthermore, the calf member 262 mayinclude a fastener element arranged to secure the calf member 262 to auser's leg.

FIGS. 28-30 show dynamic energy storage and energy return of theankle-foot orthosis 202 of FIG. 20. A person having a normal gaittypically requires between 1 and 38 mm of ground clearance in order toavoid dragging their toes over the ground and risk falling. A personlacking the strength to lift up the foot using the dorsiflexors of theankle risks dragging of the toes over the ground during a mid-swing,which is characterized as the condition called dropfoot. Consequently,individuals with dropfoot have a tendency to change their gait in orderto prevent dropfoot from occurring.

Minor support of the ankle and foot 272, as shown in FIG. 28, duringthis stage of the gait-cycle (100% consisting of 60% stance phase and40% swing phase) provides sufficient ground clearance and prevents thefoot from dragging over the ground. At initial contact, the ankle-footorthosis 200 provides an additional ankle dorsiflexion moment M (upwardmotion of the toes and foot marked), of which the user lacks due toinsufficient or impaired muscle work of the ankle dorsiflexors (mainlytibialis anterior) of the ankle. The user requires assistance in orderto achieve a more normal gait in terms of smooth loading response of theankle which results in an unforced loading response of the knee. If theheel portion of the footplate is too rigid, the ankle-foot orthosis willact like a lever that will pull the knee forward into forced flexion.Due to the footplate described herein, the flexibility of the footplatewill prevent the ankle-foot orthosis to act like a lever.

At the end of stance phase, as shown in FIG. 30, the plantarflexors ofthe ankle, need to contract in order to create sufficient power to pushthe foot off the ground and the body forward to ensure progression ofthe gait. In cases where plantarflexion muscle work is absent orimpaired, the spring will compensate or assist that function.Integrating carbon fiber into a spring design allows the spring tobenefit from the energetic characteristics of the carbon fibers. Energyis stored when the spring is compressed, in a flexed or bent condition.When the spring decompresses or deflexes, the energy E is released whichresults in a forward push of the limb which assists the limb to progressinto a swing phase, as illustrated in FIG. 30.

FIG. 31 represents a selection chart of different ankle foot orthoticdevice, divided into four categories, foot size, footplate, height ofthickest part of the calf, and proximal strap height. The selectionchart is further divided into three size categories comprising: small,medium, and large. Thus with the chart shown in FIG. 31, the ankle-footorthosis may be mass produced.

FIG. 32 shows momentum of plantarflexors and dorsiflexors during astance phase. The solid line represents the momentum for a healthy foot,while the dotted line shows the momentum for an individual havingdropfoot. An objective of the ankle-foot orthosis is to correct gaitimperfections so that it follows the path of the solid line. Thestiffness of the ankle-foot orthosis should, when dealing with adropfoot user, aim to solve the crucial momentum difference at the anklewhich occurs just after heel strike. If the ankle-foot orthosis has thecorrect stiffness to provide a normal rate of plantarflexion at heelstrike, the ankle-foot orthosis also provides sufficient groundclearance during the swing phase.

1. An orthotic footplate including top and bottom surfaces, thefootplate having a length beginning at a heel end of a heel portionextending to a middle portion, and terminating at a toe end of a toeportion, the footplate having a line of progression extending betweenthe heel and toe ends, the footplate being solely formed from: aplurality of superimposed, discrete rigid and resilient structurallayers formed from the same material and each layer having a uniformthickness and a different length defined between the heel and toe endsof the footplate; wherein the superimposed structural layers formregions with different thicknesses and stiffness along the line ofprogression, such that the footplate is rigid and resilient.
 2. Theorthotic footplate according to claim 1, wherein the heel portion andthe toe portion have less stiffness than the middle portion.
 3. Theorthotic footplate according to claim 1, wherein a lowermost structurallayer of the plurality of structural layers is coextensive with thelength of the footplate, the lowermost structural layer having upper andlower surfaces such that the lower surface defines the bottom surface ofthe footplate.
 4. The orthotic footplate according to claim 3, whereinthe lowermost structural layer generally defines the periphery of thefootplate.
 5. The orthotic footplate according to claim 3, wherein atleast one additional structural layer is disposed on the upper surfaceof the lowermost structural layer, the at least one additionalstructural layer having an area less than the upper surface of thelowermost structural layer.
 6. The orthotic footplate according to claim5, wherein the at least one additional structural layer comprises aplurality of discrete structural layers extending from the upper surfaceof the lowermost structural layer, each of the plurality of structurallayers extending across at least the middle portion of the footplate. 7.The orthotic footplate according to claim 6, wherein each of theplurality of discrete structural layers ascending from the upper surfaceof the lowermost structural layer progressively decreases in lengthrelative to the lowermost structural layer.
 8. The orthotic footplateaccording to claim 1, wherein the material of the plurality ofstructural layers comprises a plurality of fibers impregnated with apolymeric material.
 9. The orthotic footplate according to claim 8,wherein the fibers are generally oriented at an oblique angle relativeto the line of progression of the footplate.
 10. The orthotic footplateaccording to claim 9, wherein the fibers extend relative to the line ofprogression in a range of 15-75°.
 11. The orthotic footplate accordingto claim 8, wherein the polymeric material is an epoxy resin.
 12. Theorthotic footplate according to claim 8, wherein the plurality of fibersis selected from the group consisting of carbon fibers, glass fibers,Kevlar aramid fibers, and a combination thereof.
 13. The orthoticfootplate according to claim 8, wherein the fibers are unidirectionallyoriented generally parallel to the line of progression of the footplate.14. The orthotic footplate according to claim 8, wherein the fibers ofeach structural layer of the footplate are woven unidirectionally withfibers running substantially parallel to the line of progression of thefootplate.
 15. The orthotic footplate according to claim 1, wherein atleast one of the structural layers has a toe end and a heel end definedgenerally as a linear edge substantially perpendicular to the line ofprogression.
 16. The orthotic footplate according to claim 1, whereinthe footplate has a generally curvilinear profile extending along theline of progression and defined substantially perpendicular therewith.17. The orthotic footplate according to claim 16, wherein the footplatedefines greater curvature at a region extending between the heel portionand the middle portion relative to a region extending between the middleportion and the toe portion.
 18. An orthotic footplate including top andbottom surfaces, the footplate having a length beginning at a heel endof a heel portion extending to a middle portion, and terminating at atoe end of a toe portion, the footplate having a line of progressionextending between the heel and toe ends, the footplate being solelyformed from: at least two superimposed, discrete rigid and resilientstructural layers formed from the same material, and having differentlengths and extending along the length of the footplate, each of the atleast two structural layers having generally the same shape, such thatthe footplate is rigid and resilient; wherein a lowermost structurallayer has a longest length of the at least two structural layers anddefines the length of the footplate, the lowermost structural layerhaving a lower surface defining the bottom surface of the footplate. 19.The orthotic footplate according to claim 18, wherein the heel portionand the toe portion have less stiffness than the middle portion.
 20. Theorthotic footplate according to claim 18, wherein at least oneadditional structural layer is disposed on an upper surface of thelowermost structural layer, the at least one additional structural layerhaving an area smaller than the area of the upper surface of thelowermost structural layer.
 21. The orthotic footplate according toclaim 20, wherein the at least one additional structural layer comprisesa plurality of discrete structural layers extending from the uppersurface of the lowermost structural layer, each of the at least oneadditional structural layer extending across at least a portion of themiddle portion of the footplate.
 22. The orthotic footplate according toclaim 21, wherein at least some of the plurality of structural layersascending from the upper surface of the lowermost structural layerprogressively decrease in length.
 23. The orthotic footplate accordingto claim 18, wherein the footplate has a generally curvilinear profilealong a line of progression extending from a heel portion to a middleportion to a toe portion of the footplate.
 24. The orthotic footplateaccording to claim 23, wherein the footplate defines greater curvatureat a region extending between the heel portion and the middle portionrelative to a region extending between the middle portion and the toeportion.
 25. An orthotic footplate including top and bottom surfaces,the footplate having a length beginning at a heel end of a heel portionextending to a middle portion, and terminating at a toe end of a toeportion, the footplate having a line of progression extending betweenthe heel and toe ends, the footplate being solely formed from: at leasttwo superimposed, discrete resilient and regid structural layers formedfrom the same material and each having a different length extendingalong at least a segment of the length of the footplate, the at leasttwo structural layers defining regions of the footplate with differentthicknesses and stiffness, such that the footplate is rigid andresilient; wherein at least a lowermost structural layer comprises apolymeric material reinforced with a plurality of fibers.
 26. Theorthotic footplate according to claim 25, wherein the lowermoststructural layer has a lower surface defining the bottom surface of thefootplate, and extends from the heel end to the toe end of thefootplate.
 27. The orthotic footplate according to claim 26, wherein anuppermost structural layer has an upper surface defining the top surfaceof the footplate, a clearance is defined between the toe and heel endsof the lowermost structural layer and the uppermost structural layeralong the line of progression of the footplate.
 28. The orthoticfootplate according to claim 27, wherein a clearance is defined betweenthe entirety of the periphery of the lowermost structural layer and theentirety of the periphery of the uppermost structural layer.
 29. Theorthotic footplate according to claim 27, wherein at least one middlestructural layer is located between the lowermost structural layer andthe uppermost structural layer, the at least one middle structural layerhaving a length less than the lowermost structural layer.
 30. Theorthotic footplate according to claim 29, wherein the at least onemiddle structural layer has a length greater than the uppermoststructural layer.
 31. The orthotic footplate according to claim 25,wherein each structural layer has a substantially uniform thickness. 32.The orthotic footplate according to claim 25, wherein each structurallayer has a substantially similar uniform thickness.
 33. An orthoticfootplate including top and bottom surfaces, the footplate having alength beginning at a heel end of a heel portion extending to a middleportion, and terminating at a toe end of a toe portion, the footplatehaving a line of progression extending between the heel and toe ends,the footplate being solely formed from: a plurality superimposed,discrete rigid and resilient structural layers all constructed from apolymeric material impregnated with a plurality of fibers, eachstructural layer having a uniform thickness and a different lengthdefined between the heel and toe ends of the footplate, such that thefootplate is rigid and resilient; wherein a lowermost structural layerhas a longest length and defines the length of the footplate, thelowermost structural layer having a bottom surface defining the bottomsurface of the footplate.